Caterpillar D5k Dozer Operation Manual

Full download: http://manualplace.com/download/caterpillar-d5k-dozer-operation-manual/ SEBU8213-04

October 2009

Operation and
Maintenance
Manual
D3K, D4K and D5K Track-Type
Tractors
JTD1-Up (Machine)
FFF1-Up (Machine)
JLF1-Up (Machine)
LLL1-Up (Machine)
MMM1-Up (Machine)
RRR1-Up (Machine)
WWW1-Up (Machine)
YYY1-Up (Machine)

SAFETY.CAT.COM

This is the cut pages sample. Download all 144 page(s) at: ManualPlace.com
 i03684547

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU8213-04 3
Table of Contents

Table of Contents Adjustments .......................................................... 71

Parking .................................................................. 73
Foreword ................................................................. 4
Transportation Information .................................... 77
Safety Section Towing Information ................................................ 81
Safety Messages .................................................... 6
Engine Starting (Alternate Methods) ..................... 82
Additional Messages ............................................. 12
Maintenance Section
General Hazard Information ................................. 15
Lubricant Viscosities and Refill Capacities ........... 84
Crushing Prevention and Cutting Prevention ........ 17
Maintenance Support ............................................ 88
Burn Prevention .................................................... 18
Maintenance Interval Schedule ............................ 89
Fire Prevention and Explosion Prevention ............ 18
Reference Information Section
Fire Extinguisher Location .................................... 22
Reference Materials ............................................ 137
Track Information .................................................. 22
Index Section
Electrical Storm Injury Prevention ......................... 22
Index ................................................................... 140
Before Starting Engine .......................................... 22

Engine Starting ..................................................... 22

Before Operation .................................................. 23

Visibility Information .............................................. 23

Operation .............................................................. 23

Parking .................................................................. 24

Slope Operation .................................................... 24

Engine Stopping ................................................... 25

Equipment Lowering with Engine Stopped ........... 25

Sound Information and Vibration Information ....... 25

Guards (Operator Protection) ............................... 28

Product Information Section

General Information .............................................. 30

Identification Information ....................................... 32

Operation Section
Before Operation .................................................. 37

Machine Operation ............................................... 39

Engine Starting ..................................................... 69

4 SEBU8213-04
Foreword
Foreword
Literature Information
This manual should be stored in the operator's
compartment in the literature holder or seat back
literature storage area.
This manual contains safety information, operation
instructions, transportation information, lubrication
information and maintenance information.
Some photographs or illustrations in this publication
show details or attachments that can be different
from your machine. Guards and covers might have
been removed for illustrative purposes.
Continuing improvement and advancement of
product design might have caused changes to your
machine which are not included in this publication.
Read, study and keep this manual with the machine.
Whenever a question arises regarding your machine,
or this publication, please consult your Caterpillar
dealer for the latest available information.
Safety
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations
of warning signs and labels used on the machine.
Read and understand the basic precautions listed
in the safety section before operating or performing
lubrication, maintenance and repair on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced
operator. This section includes a discussion of
gauges, switches, machine controls, attachment
controls, transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval. Items without specific intervals are listed
under the "When Required" service interval. The
Maintenance Interval Schedule lists the page
number for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Maintenance Interval Schedule as an index or "one
safe source" for all maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
be necessary.
Perform service on items at multiples of the original
requirement. For example, at every 500 service
hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
10 service hours or daily.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
Certified Engine Maintenance
Proper maintenance and repair is essential to keep
the engine and machine systems operating correctly.
As the heavy duty off-road diesel engine owner, you
are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.
SEBU8213-04 5
Foreword

It is prohibited for any person engaged in the 3. Check Character (character 9)

business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or
render inoperative any emission related device or
element of design installed on or in an engine or
machine that is in compliance with the regulations
(40 CFR Part 89). Certain elements of the machine
and engine such as the exhaust system, fuel system,
electrical system, intake air system and cooling
system may be emission related and should not be
altered unless approved by Caterpillar.
Machine Capacity
4. Machine Indicator Section (MIS) or Product
Sequence Number (characters 10-17). These were
previously referred to as the Serial Number.
Machines and generator sets produced before First
Quarter 2001 will maintain their 8 character PIN
format.
Components such as engines, transmissions, axles,
etc. and work tools will continue to use an 8 character
Serial Number (S/N).

Additional attachments or modifications may exceed

machine design capacity which can adversely affect
performance characteristics. Included would be
stability and system certifications such as brakes,
steering, and rollover protective structures (ROPS).
Contact your Caterpillar dealer for further information.

Caterpillar Product Identification

Number
Effective First Quarter 2001 the Caterpillar Product
Identification Number (PIN) has changed from 8 to 17
characters. In an effort to provide uniform equipment
identification, Caterpillar and other construction
equipment manufacturers are moving to comply
with the latest version of the product identification
numbering standard. Non-road machine PINs are
defined by ISO 10261. The new PIN format will apply
to all Caterpillar machines and generator sets. The
PIN plates and frame marking will display the 17
character PIN. The new format will look like the
following:

g00751314
Illustration 1

Where:

1. Caterpillar's World Manufacturing Code (characters

1-3)

2. Machine Descriptor (characters 4-8)

6 SEBU8213-04
Safety Section
Safety Messages

Safety Section
i03193580

Safety Messages
SMCS Code: 7000; 7405

g01357030
Illustration 2
SEBU8213-04 7
Safety Section
Safety Messages

g01357376
Illustration 3

There are several specific safety messages on this

machine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiarized with all safety
messages.

Make sure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if you cannot read the words. Replace
the illustrations if the illustrations are not visible.
When you clean the safety messages, use a cloth,
water, and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
g01359794
the adhesive that secures the safety message. Loose
Illustration 4 adhesive will allow the safety message to fall.
8 SEBU8213-04
Safety Section
Safety Messages

Replace any safety message that is damaged or Seat Belt (2)

missing. If a safety message is attached to a part of
the machine that is replaced, install a safety message Safety Message (2) is positioned on the left hand
on the replacement part. Any Caterpillar dealer can side of the cab post in view of the operator.
provide new safety messages.

Do Not Operate (1)

Safety Message (1) is positioned on the right hand
side of the cab post in view of the operator.

g01030982 g01371636

Do not operate or work on this machine unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement manu-
als. Proper care is your responsibility.
A seat belt should be worn at all times during ma-
chine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.
SEBU8213-04
Do Not Weld On the ROPS (3)
Safety Message (3) is positioned on the left rear side
of the cab post.
g01398698
Structural damage, an overturn, modification, al-
teration, or improper repair, can impair this struc-
ture's protective capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure's limitations without voiding
its certification.
This machine has been certified to the standards that
are listed on the certification plate. The maximum
mass of the machine, which includes the operator
and the attachments without a payload, should not
exceed the mass on the certification plate.
9
Safety Section
Safety Messages
Product Link (4) (if equipped)
Safety message (4) is located in the left side of the
cab on the front support.
g01108685
This machine is equipped with a Caterpillar Prod-
uct Link communication device which must be de-
activated within 12 m (40 ft) of a blast zone. Failure
to do so could result in serious injury or death.
Refer to Special Instruction, REHS1642, “Operation
of the Product Link System” for additional information.
No Ether in Air Inlet (5)
Safety Message (5) is located on the left side of the
engine on the air cleaner cover. Only use the ether
starting aid group that is factory installed for safety.
g01055438
Do not use ether. This machine is equipped with
glow plugs. Using ether can create explosions or
fires that can cause personal injury or death. Read
and follow the engine starting procedure in the
Operation and Maintenance Manual.
Caterpillar D5k Dozer Operation Manual
10
Full download: http://manualplace.com/download/caterpillar-d5k-dozer-operation-manual/ SEBU8213-04
Safety Section
Safety Messages

High Pressure Fuel Lines (6) Hot Fluid Under Pressure (8)
Safety Message (6) is located on the left side of the Safety Message (8) is located under the access door
engine on the high pressure fuel rail. on the expansion tank filler cap.

g01381180 g01370913

Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.

High Pressure Cylinder (7)

Safety Message (7) is located on the track adjuster
cover that is on the outside of the track roller frame.

g01357122

High Pressure Cylinder. Do not remove any parts

from the cylinder until all of the pressure has been
relieved. This will prevent possible personal injury
or death.

This is the cut pages sample. Download all 144 page(s) at: ManualPlace.com